Wood filler composition



Patented Sept. 18, 1951 woon FILLER COMPOSITION T Edward R. Bush, *Iieni'ont, 111i, and Joh'nE. Harrie; 1 Westfield; N: J1," as'signors to InterchemicalCo'i poratio'n, New- York, N. -Y.-,-'a-'corporation of Ohio No Drawing. Applicationjanuary ,1947;

v s lial N- 721,161

. v 1 This'invention relates compositions" for filling the pores of the wood which is later to be coated with a finishingeoat ing.

In the past, woodfillershavegenerally consisted of ve'ry'hi'ghlypigmented oils oroleoresihou's varnishes; In conventional practice; these 'One of the major disadvantages with the conventional oil-type'wood fillers is that usually several hours are "required for the fillers to drybefore a top coat of lacquer or varnish can beapplied. Other disadvantages of these oil-type fillers arethattOp or finish coats have poor adhesion to the filled surface and they often exhibit'shrinkage after application (a sinkingin at the pores of the'woo'd).

An object of the present invention is toprovide a novel type of wood filler that can be applied in conventionalmanner as by spraying or brush ing and then can bewipedwithin a few minutes and coated over with a lacquer or other woodfinish coating immediately thereafter. The use of such, a wood filler obviously eliminates the usual lengthy-drying period encountered inthewood filling operation; Other objects of the invention Will be apparent from the'descriptio'n of the invention which follows hereinafter.

' The novel Wood fillers of this invention con- 'sist essentially of emulsions of the usual pigments, including prime-and extender pigments, in a mixture of two incompatible vehicles characterized in that the incompatible vehicles do not precipitate each other on mixingto form the emulsion. One of the vehicles is preferably an oleoresinous varnish, such as China-wood oilphenolic resin varnish or- China-wood oil-maleated rosin ester varnish. The other vehicle is a convertible resin, preferably a phenolic resin, such as that-obtained by condensing phenol with an excess of formaldehyde, dissolved in a volatile solvent such as alcohols, esters, ketones, and the like. 'Mixing'oftheoleoresinous varnish and the phenolic resinsolution with the pigments gives an emulsified paste ofunifo'rm consistency, in whichrthe particles of pigment appear to serve to improved wood filler 5 Claims; (01. 260'119)' to be employed will necessarily as emulsifiers, by being partially wetted byboth" i :2 thewarhishQand phenolic re ventprecipitation or-separationfof teammate nents of the composition. f-

.1 When the Wood-filler, i-irihabfiv'dscl ibfl, I

is applied to a wood surface, the articms apseas to orient themselves, asthe solvent evaporates, in such a; manner that the oleoresinous varnish migrates-' to the top "surface -and- 'the-plfnlilrf resin penetrates-the pores-ofthe worse-teams the pigment particles-with -itr a =result tl ie' ole'ore'sinous Varnish-*Whichrises-to -the s 'rf' e serves asa lubricant-for the-wiping pe l}; while the pigment particlesand" 'phi-i ic- -resih remain ih"th ej poresofthe woodk I wi ewiping operation; after wiping---with-a* dry anth m I ventional manner, it hasbeen found beneficial to; wipe with the grain; with-- a-clothwet with a; solvent for the varnish in order to remove the; last tracesiof the varnisha- The Wood fillers preparedaccording to the invention dry by evaporationv of solvent and, hardening of ,theccbnvertible resin-anddonot depend upon the oxidationa-of; a:- dry-ingoil as would: be necessary-in the dryingof: the convene tionai' 'oil or varnish-type fillers. Consequentlw by the'use of dour-novel wood filler-s inaewooidrfinishing schedule; i there: :isa considerable short: ening of the overall finishing schedules 7 Advantageouslyl,-the woodfillers of thei preseiit invention-are prepared by mixing'and' kneading? the pigments with" both the'ya rnish and the: phenolic-resinsolution; A mutua'l solvent-such Cellosolve (ethyl ether of ethylene glycolwButyl Cellosolve (butyl ether of ethyl glycol), etc., is added to:- the 'mi gture to reduce the consistencyto proper workability fo facilitate appl ic ion of the filler compositionito wga su rr ae,/a may e fu er. r d c d w th" e ade ed-ame et of v a Solvents such. asale h l ;petr leum: hydrocarbons, and the lil re, or with mixtures of these, or mixtures of these'solvents with the Cellosolves, e'the'rs: andestersi" Thefiller'compositicnmaybefurtlirfiiiodifiedf to give fast dryin admixing the fille' 1 g, steamer tempos 1 ns ty- H i I18. I tilt. of Water-s'oluble'dy' dissolvedifi or'gahic sdl-' vents. The amount' of suchstaining ingredients depend upons'the degreeoi shade of staining.desired.'

The phenolic-resinsusedin the bdd filli at? preferahIy'madby coridnsih he bl' with cess forinaldehyde in the pres'ehc or 1 n all'lefliiie catalyst as describedin United-sta'tes l atentlNifi 2,114,784, patented Apr' 19, 1938. 'I ypicallyrone mole of' phenol and .215 mines: of formaldehyde- (as-3 7 per cent 'aeo s'olutionfare condensed by refluxing in=the presence of a catalytieamount of sodiun'icarbonate for 3 to 3% hours; --'Ifhe 'solutionto are alkali is' then neutralized with lactic acid and the reaction mixture'cut to 50 per cent solids with butyl alcohol. At this point, the water separates as a top layer and contains th soluble salts formed by the neutralization of the alkali. The non-aqueous layer, consisting of a butyl alcohol solution of the phenolic resin, is separated for use in the wood filler composition;

In the production of the wood fillers according to this invention, the phenolic resin may be mixed with other resins such as vinyl resins, and cellulose derivatives, which are soluble in solvents which will dissolve the phenol-formaldehyde resin. When such resins are used they will generally constitute less .than per cent of the total resin. Typically, 1 per cent of polyvinyl butyral may be added to the phenol-formaldehyde resin solution.

.The following examples further illustrate the invention:

Example I v Parts by weight Quartz 40 lbs. Velveteen silica 146 lbs. Carbon black 17 oz.

12 lbs., 11 oz. 171bs., oz.

Burnt Italian Sienna Burnt Turkey umber Phenolic resin vehicle 60 lbs. China-wood oil varnish 39 lbs. Butyl Cellosolve 39 lbs.

The above ingredients are mixed to give a thoroughly emulsified wood paste. Thi composition maybe cut to desired spraying or brushing consistency by the addition of volatile organic solvents such as ethers, alcohols, ketones, esters or petroleum spirits.

Y. The particular China-wood oil varnish used in th above formulation was prepared by first cookmg 120 parts of maleated rosin ester (Amberol) into 94 parts of China-wood oil at a temperature of about 500 F. in the presence of about 0.2 parts of manganese acetate and cutting the cook with 40 gallons of petroleum hydrocarbon solvent (Varnolene). This varnish vehicle is then admixed with further quantities of heat bodied China-wood oil, drier and solvent to giv the China-wood oil varnish used in the formulation. The proportions by volume are as follows:

Parts by volume Varnish vehicle I parts 16 Varnolene (petroleum hydrocarbon solvent) do 39 Heat bodied China-wood oil do 9' Drier solution do 5 The drier solution was made by dissolving 166 pounds cobalt linoleate paste (Harshaw Chemical Co. Paste #42) in 58 gallons of petroleum hydrocarbon solvent (Varnolene).

Stained filler compositions can be made by incorporating one or more soluble dyes into the filler. The following example is typical.

. Example II Quartz 1 1b., 8 oz. Velveteen silica 4 1b., 8 oz. Van Dyke brown 1 lb.

Phenolic resin vehicle of Example I 1 1b., 8 oz. China-wood oil varnish of Example I 1 lb. Butyl Cellosolve 1 lb.

' To this filler composition was added an equal volume of a stain composition consisting of 1.5 oz. Aniline Powder Walnut, 12 oz. Methyl Cellosolve,"84 oz. methyl alcohol, 0.125 oz. Crocein Scarlet, 1 oz. Resorcin Brown GN, 0.375 oz. Black 4 Stain Powder B-34951 (National Aniline Division, Allied Chemical and Dye Corporation) to give a walnut stain filler composition.

Since the composition of the filler may vary considerably and depends for the most part on the users particular needs, it will be impractical to set definite percentage limitations for all of the constituent of the composition. However, as regards the varnish and resin vehicle, we prefer to use from 1 to 2 parts by weight of resin vehicle to 1 part by weight of the varnish vehicle.

The wood fillers prepared according to our invention. are faster drying than the conventional type fillers. Furthermore, they provide improved adhesion of the top or finish coat to wood surfaces without subsequent shrinkage of the final finish.

We claim:

1. A composition of matter suitable for use as a wood filler comprising pigment dispersed in a vehicle comprising an emulsion of an oleoresinous varnish and a volatile organic solvent,

solution of a thermosetting resin which is incompatible with the oleoresinous varnish, said emulsion being of the non-aqueous type.

2. A composition of matter suitable for use as a wood filler comprising pigment dispersed in a vehicle comprising an emulsion of an oleoresinou varnish and a volatile organic solvent solution of a thermosetting phenol-formaldehyde resin which is incompatible with the oleoresinous varnish, said emulsion being of the non-aqueous type.

3. A composition of matter suitable for use as a wood filler comprisingpigment dispersed in a vehicle comprising an emulsion of an oleoresinous varnish and a volatile organic solvent solution of an alkali-condensed thermosetting phenol-formaldehyde resin which is incompatible with the oleoresinous varnish, said emulsion being of the non-aqueous type.

4. A composition of matter suitable for use as a wood filler comprising pigment dispersed in a vehicle comprising an emulsion of a China-wood oil-phenolformaldehyde resin varnish and a volatile organic solvent solution of an alkali condensed phenol-formaldehyde resin which is incompatible with the said varnish, said emulsion being of the non-aqueous type.

5. A composition of matter suitable for use as a wood filler comprising pigment dispersed in a vehicle comprisin an emulsion of an oleoresinous varnish and a volatile organic solvent solution of an alkali-condensed phenol-formaldehyde resin which is incompatible with the oleoresinous varnish, and the volatile solvent ingredients of said emulsion containing a watersoluble dye dissolved therein, said emulsion being of the non-aqueous type.

EDWARD R. BUSH. JOHN E. HANLE.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

1. A COMPOSITION OF MATTER SUITABLE FOR USE AS A WOOD FILTER COMPRISING PIGMENT DISPERSED IN A VEHICLE COMPRISING AN EMULSION OF AN OLEORESINOUS VARNISH AND A VOLATILE ORGANIC SOLVENT SOLUTION OF A THERMOSETTING RESIN WHICH IS INCOMPATIBLE WITH THE OLEORESINOUS VARNISH, SAID EMULSION BEING OF THE NON-AQUEOUS TYPE. 